# US 2014/0150634 A1 · Composite structure and method of making a composite structure

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- Number: US 2014/0150634 A1
- Document ID: US20140150634A1
- Status: Published application
- Kind: A1
- Application number: 13/897,795
- Filed: 2013-05-20
- Published: 2014-06-05
- Earliest claimed: 2012-05-18
- Assignees: Board of Trustees of Michigan State University
- Applicants: Board of Trustees of Michigan State University
- Inventors: Dahsin Liu; Chun-Ying Lee; Chian-Fong Yen; Corey Anderson; Guojing Li
- Web page: https://patentgrep.com/patent/US20140150634A1

## CPC

- F41H 5/0485: {all the layers being only fibre- or fabric-reinforced layers}
- B29C 70/222: {the structure being shaped to form a three dimensional configuration}
- B29C 70/24: oriented in at least three directions forming a three-dimensional [3D] structure
- B29C 70/342: {using isostatic pressure}
- F41H: ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

In accordance with the present teachings, a method of producing composite having a 3A Q3D reinforcement phase is disclosed. The method of producing the composite provides producing a three-dimensionally woven configuration where a first fiber from a first sheet of reinforcement phase is interwoven or mechanically linked with at least one of an adjacent second layer and then back into the first sheet. The linking fibers are passed between layers at an acute angle generally less than about 10 degrees. The method includes impregnating the woven construction with a curable polymer such as epoxy.

## Claims

### Claim 1

A composite structure comprising:
a first fiber composite layer having a first reinforcing layer having a plurality of first fibers having a respective relative fiber directions of about 0°, and 60° and −60°;
at least a second fiber composite layer having a first reinforcing layer having a plurality of second fibers having a respective relative fiber directions of about 0°, and 60° and −60°, in relation to the first composite layer, the layers being secured together adjacent each other in an overlapping manner; and
an inter-layer fiber being woven within both the first and third reinforcing layers.

### Claim 2 (depends on 1)

The composite structure of claim 1, further comprising a fourth skin composite layer attached to an opposite portion of at least one of the first and second composite layers, the third and fourth composite layers being substantially parallel and spaced apart from each other, wherein the inter-layer fiber is woven within the fourth layer.

### Claim 3 (depends on 1)

The composite structure of claim 1, further comprising an optically clear matrix, and wherein the first fibers and second fibers are optically clear.

### Claim 4

A composite structure comprising:
a first fiber composite layer having a relative fiber direction of about 0°;
and at least a second fiber composite layer having a relative fiber direction of between about 60° and 31 60°, inclusive, compared to the first composite layer, the layers being secured together and adjacent each other in an overlapping manner; and
a plurality of inter-layer fibers knit into both the first and second composite layers.

### Claim 5 (depends on 4)

The composite structure of claim 4, a plurality of fibers being woven in the first and passed through the second composite layer.

### Claim 6 (depends on 5)

The composite structure of claim 5, further comprising a third composite layer attached between the first and second fiber composite layers by a second plurality of inter-layer fibers.

### Claim 7 (depends on 5)

The composite structure of claim 5, wherein the composite structure provides aircraft armor operable to substantially stop complete bullet-like projectile perforation.

### Claim 8 (depends on 5)

The composite structure of claim 5, wherein the composite structure provides land vehicle armor operable to substantially stop complete bullet-like projectile perforation.

### Claim 9

A composite structure comprising:
a first fiber composite layer having a relative fiber direction of about 0°;
and at least a second fiber composite layer having a relative fiber direction of between about 60° and −60°, inclusive, compared to the first composite layer, the layers being secured together adjacent each other in an overlapping manner, at least a section of a reinforcement of the first composite layer being disposed between the first and second fiber composite layers and woven into the second fiber composite layer.

### Claim 10 (depends on 9)

The composite structure according to claim 9 wherein the fibers are three-dimensionally woven and interlinking between the composite layers.

### Claim 11

A composite structure comprising:
a first unit fiber composite layer;
a second unit fiber composite layer;
at least a third unit fiber composite layer; and
resin secured to at least one of the composite unit layers, the unit layers being three-dimensionally woven together with fibers from the first unit composite layer being mechanically linked to fibers from the at least unit third or a deeper composite layer, and fibers from the first unit composite layer being mechanically linked to fibers from the unit second layer.

### Claim 12 (depends on 11)

The composite structure of claim 11, wherein the composite unit layers comprise at least one of a curved or non-planar section.

### Claim 13 (depends on 12)

The composite structure of claim 12, further comprising a fourth skin composite layer attached to only a tangent of the one of the curved or non-planar section.

### Claim 14 (depends on 11)

The composite structure of claim 11, wherein the composite layers define a cylindrical shape.

### Claim 15 (depends on 11)

The composite structure of claim 11, wherein the composite layers define a substantially semi-spherical shape.

### Claim 16 (depends on 11)

The composite structure of claim 11, wherein the composite layers define a repeating corrugated shape.

### Claim 17 (depends on 11)

The composite structure of claim 11, wherein the composite layers provide aircraft armor operable to substantially stop complete bullet-like projectile perforation.

### Claim 18 (depends on 11)

The composite structure of claim 11, wherein the composite layers provide land vehicle armor operable to substantially stop complete bullet-like projectile perforation.

### Claim 19 (depends on 11)

The composite structure of claim 11, wherein fibers in one of the composite layers are oriented at or between 60° and −60° relative to an adjacent composite layer.

### Claim 20

A composite structure comprising:
a first tubular member;
a second tubular member annularly disposed about the first tubular member; and
a third tubular member having a smaller cross sectional size compared to the first tubular member; and
a linking fiber phase disposed between the first, second and third tubular member, wherein each of the tubular members includes at least two composite sheets with offset angled fibers from one sheet relative to an adjacent sheet, the first, second and third tubular members having a fiber bundle woven between the first and second tubular members at an angle less than 10° relative to a tangent to the first tubular member.

### Claim 21 (depends on 20)

The composite structure of claim 20, wherein the linking fiber phase defines a portion of each of the first and second tubular members.

### Claim 22

A method of making a composite structure, the method comprising:
(a) locating a first circular row of fibers oriented with a first fiber direction;
(b) locating a second circular row of fibers interposed with the first circular row, oriented with a second fiber direction offset from the first fiber direction by about 60° −60°, inclusive;
(c) locating a third circular row of fibers oriented with the first fiber direction;
(d) knitting a plurality of fibers in both the first and third circular rows to form a 3A Q3D reinforcement phase;
(e) impregnating the first, second, and third circular rows with uncured epoxy;
(f) applying a vacuum to the sheets;
(g) curving at least a portion of the sheets; and
(h) curing resin in the sheets so that the sheets are bonded together, the curved portion remaining curved after the curing.